Electrical Troubleshooting Information

Before Troubleshooting 

1. Check applicable fuses in the appropriate fuse/relay box.

2. Check the 12 volt battery charge and whether the 12 volt battery has been damaged, and clean and tighten the connections.

NOTICE: 

• Do not quick-charge a 12 volt battery unless the 12 volt battery ground cable has been disconnected, otherwise you will damage the alternator diodes.
• Do not attempt to crank the engine with the 12 volt battery ground cable loosely connected or you will severely damage the wiring.

3. Check the drive belt tension.

Handling Connectors 

• Make sure the connectors are clean and have no loose wire terminals.
• Make sure multiple cavity connectors are packed with dielectric grease (except waterproof connectors).
• Most of the connectors have push-down release type locks (A).

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• Some connectors have a clip on their side used to attach them to a mounting bracket on the body or on another component. This clip has a pull type lock.
• Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket (A).

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• Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead.
• Always reinstall plastic covers.

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• Before connecting connectors, make sure the terminals (A) are in place and not bent.

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• Check for loose retainers (A) and rubber seals (B).

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• The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace the connector (if available) or the wire harness.

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• Insert the connector all the way and make sure it is securely locked.
• Position wires so that the open end of the cover faces down.

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Handling Wires and Harnesses 

• Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations.
• Remove clips carefully; do not damage their locks (A).

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• Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip.

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• After installing the harness clips, make sure the harness does not interfere with any moving parts.
• Keep the wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts.
• Seat grommets in their grooves properly (A). Do not leave grommets distorted (B).

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Testing and Repairs 

• Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape.
• Never attempt to modify, splice, or repair SRS wiring. If there is an open or damage on SRS wiring or terminals, replace the harness.
• After installing parts, make sure that no wires are pinched under them.
• When using electrical test equipment, follow the manufacturer's instructions and those described in this service information.
• If possible, insert the probe of the tester from the wire side (except for waterproof connectors).

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• Use a probe with a tapered tip.

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When checking any control module(s) or unit(s) connector terminals, gently slide the sharp tester probe from the wire side into the connector until it comes in contact with the terminal end of the wire.

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• Some vehicles may use an aluminum wire harness (wire color: light purple). Special attention is needed to protect the harness from corrosion and damage during disconnecting of connectors.
• • Do not break up the connectors of the aluminum wire harnesses.
  • Never attempt to modify and repair the aluminum wire harnesses. Replace the wire harnesses if they are damaged.